Toner cartridge Replace faulty toner cartridge | Lexmark 5021-0XX

5021-0XX

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3 Toner cartridge

Replace faulty toner cartridge.

Diagnostic information 2-117

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Lexmark 5021-0XX manual Toner cartridge Replace faulty toner cartridge

Contents

Revised March 24 United States Government Rights 5021-0XX Table of contents Diagnostic information 5021-0XX Diagnostic aids Vii 5021-0XX Locations and connectors 5021-0XX Laser notices Laser advisory label Class 1 Laser statement label Laser Laser notice Avvertenze sui prodotti laser Avis relatif à l’utilisation de laser Avisos sobre el lá ser Lasermeddelelse Laserinformatie Laser-notis Huomautus laserlaitteesta Avís sobre el Là ser Laser-melding Japanese laser notice Chinese laser notice Korean laser notice Consignes de sé curité Safety information Sicherheitshinweise Norme di sicurezza Informaçõ es de Seguranç a Pautas de Seguridad Informació de Seguretat 5021-0XX Definitions Preface Tools required for service Maintenance approach Serial number Acronyms Model differences SpecificationsResolution Technical specifications Width Depth Height Weight4 Inch Printers Physical specifications and weight Operating clearances Packaging and shipping dimensions 500 MHz General information Print speed and performanceTime to first print Processor Paper and media specifications Duty cyclePrinter memory Sources and capacities C510/C510n C510dtn 5021-0XX Input and output configurations 5021-0XX Media input types and weights JIS B53 Media sizes Envelopes Output capacity by media and sourceMedia guidelines Paper Transparencies LabelsGlossy Paper Connections ConnectivityCables Personal computers IBM AS/400 Power and electrical specifications Environment Environment Specifications Printer identification Options identification Printer theory of operation Printer paper path Printer systems description Basic principles of color printingMechanical and electrical structures 5021-0XX Control system Printer component systems Basic process of color printing Print system and transfer system Structure of OPC belt photo developer cartridge Basic structure of the print system CBV DBV Charging process Details of the print system 5021-0XX Exposing process Developing process DBV First transfer drum process Toner image is then transferred to paper Belt discharge erase lamp process Belt cleaning process 5021-0XX Second transfer paper process Details of the transfer system Transfer belt cleaning process Description Details of the optical system 5021-0XX Part Function Details of the paper transportation system 5021-0XX Fusing unit 5021-0XX Fusing process Electrical system and function Control system structure Control of print process Control block diagram Print sequence diagram Laser drive control circuit Interface control Interface typeInterface connection 5021-0XX Start Diagnostic information Service error codes Go to 913-Fuser fan service check on Go to 910-Developer motor service check onGo to 911-Main motor service check on Go to 912-Power supply fan service check on RIP board. Go to RIP board removal on Go to 920-Fuser thermistor service check onGo to 921,922,923,924,925-Fuser assembly Go to 930,931,932-Laser unit assembly service Board removal on Controller board removal onPanel cable removal on To RIP board removal on Download emulations on Go to 986-Duplex connection error 2 service Go to 985-Duplex connection error 1 service Go to 993-Fuser clutch service check on Go to 990-Transfer belt unit service check onGo to 991-Transfer roller clutch service check Go to 992-Transfer belt cleaning roller clutch Paper size sensing service Cover open service checkOperator messages 5021-0XX Performing Self Test TMA Go to Output tray full To Paper size sensing Empty service check onCartridge service check on To Incorrect media service 5021-0XX Insufficient Memory and Held Memory may be defective 5021-0XX Configuration Change Waste toner bottle service Missing service check on Removal on Assembly removal onFuser assembly removal Engine controller board Go to Toner low/empty Paper jam messages Engine controller board removal Paper guide C assemblyPaper exit assembly removal on Board. See I/O board removal Feed assembly removal on See Duplex unit assemblyProblem, see Paper feed service Assembly. See Secondary paper Printer symptom table Symptom tables See Service error codes on See White band service checkSee Printer no power service See Waste toner feed service Print quality symptom table See Back stain service check on See Mottle service check onSee Residual image service See Insufficient gloss service Yellow developer clutch service check Printer service checks Interlock switch Locations on Magenta developer clutch service check 5021-0XX Cyan developer clutch service check 5021-0XX Black developer clutch service check 5021-0XX Yellow toner retract solenoid service check Engine Controller Board removal Magenta toner retract solenoid service check 5021-0XX Cyan toner retract solenoid service check 5021-0XX Black toner retract solenoid service check 5021-0XX 4-32. Go Developer motor service checkSee Developer Motor removal On page 4-70for steps to Switch locations on Board cage 4-57. GoSee Engine Fuser Main motor service check Assembly Main motor4-38. Go Board removal Fan removal on Power supply fan service checkPower supply Interlock switch Locations on Removal on Fuser fan service checkInterlock switch Cover assembly See Rear Laser fan service check Interlock switch Removal onLaser unit fan Erase lamp service check Erase lamp Removal onErase lamp 5021-0XX Toner empty sensor sender-TPD service check See Engine controller Board removal onSensor sender removal On page 4-35for steps Receiver Toner empty sensor receiver-TTR service checkSee Engine controller Toner sensor Hvps connection service check Right cover removal on Lower feed unit secondary paper assembly service check Fuser thermistor service check See Fuser assemblyRemoval on See Engine 921,922,923,924,925-Fuser assembly service check Removal on 4-24. Go 930,931,932-Laser unit assembly service checkLaser unit Printhead Duplex connection error 1 service check Duplex connection error 2 service check Bracket Transfer belt unit service checkTransfer belt Unit removal For 5 VDC from pin 9 to Replace faulty Transfer roller clutch service check ClutchOn page 4-70. If Transfer belt cleaning roller clutch service check Cleaning rollerClutch removal Right cover removal on Clutch Fuser clutch service check 4-69. If OPC belt marker sensor service checkRemoval on page 4-70for Marker sensor For 5 VDC from pin 11 to Replace faulty Photodeveloper Cartridge removal On page 4-11 . Has High voltage power supply Hvps service checkPhotodevelop Er cartridge High voltage Power supply Hvps removal On page 4-59. Has Low voltage power supply Lvps service check Voltage power supply Lvps with cage Removal onController board removal Board removal On page 4-55. Does Cover open service check Cable that connects to Cover interlock switch pin Incorrect media service check With cage Removal on Paper guide Missing photodeveloper cartridge service check High voltage Power supplyPhotodevelop Er cartridge Present sensor Missing toner cartridge service check On page 4-70. If Present sensor Board removal See Toner See Main See Main drive OPC belt photodeveloper cartridge drive service checkMotor Gear assembly Assembly Removal on Photodevelop Er cartridge Removal on Operator panel service check Controller board removal On page 4-55. DoesRIP board Removal on Board removal See Paper exit Output tray full service checkOn page 4-70. If Assembly See Paper exit 9 to output tray full Paper size sensing service check Left tray guide Operator Printer no power service check 4-60for Board cage removal on Toner feed service check Developer Retract solenoid Drive assembly Cam Removal onSee Developer Motor removal 4-35and Toner low/empty service checkOn page 4-70. Does error See Engine Sensor sender Registration Transfer roller missing service checkHvps cage 4-62and 5021-0XX Tray empty service check Assembly removal on Paper guide On page 4-70. If Paper guideSee Paper guide C Bottle holder removal on Waste toner bottle service checkWaste toner Bottle holder Waste toner feed service check Paper feed service checks Printer paper feed service checkRegistration assembly removal on 5021-0XX Photodeveloper cartridge Print quality service checksBackground service check Background is smeared due to toner spread Backside of paper is stained Back stain service check Banding service check Banding line appears in horizontal directionSee Photodeveloper cartridge Fine black line appears in printer image Black line service check Color misregistration between two colors Color misregistration service check Transfer belt unit removal on Printed image is partially missing Insufficient fusing service check Gloss on paper is not sufficient Insufficient gloss service check Cartridge removal on Jitter service checkMain motor assembly removal on Assembly. See Developer drive Image has missing or peeling toner at edge Missing image at edge service check Toner retract solenoid and cam Mixed color image service checkMixed color image appears Clutch removal on See Transfer roller removal on Mottle service checkVoltage power supply Hvps Variation of optical density is found in image Residual image service check See Transfer belt cleaning rollerImage of preceding page appears on every other Light print occurs in right or left side of image Ribbing service check Solenoid and cam removal on Removal on page 4-6 . Prior to Toner drop service checkAuger removal on Waste toner feeder removal on Toner cartridge Replace faulty toner cartridge Vertical line appears in printed image Vertical line service check Vertical staggering image service check Laser unit assembly printheadPrinted image staggers in vertical direction White band appears in vertical direction of printed image Vertical white band service check See Clutch removal on White band service checkHorizontal white banding creates missing portion of image Transfer roller removal on Print quality test pages on White line I service check White line II service check White spot / black spot service check White spot and black spot appear on paperBelt unit see Transfer belt unit System. See Toner retract solenoid White print service checkReinstall. See Transfer roller Removal on page 4-8 . Ensure Wrinkle / image migration service check Uneven density right and left Transfer belt unit Replace faulty transfer belt unit. See Spacing table Roller specifications 5021-0XX Disabling download emulations Select the Disable Option Go to Paper jam messages on page 2-22for more information Paper jam sequence 5021-0XX Paper Jam Diagnostic mode Diagnostics menu structure Print quality test pagesPrint Quality Description Setting tray 2 left margin Print registrationSelect Registration Select Left Margin Adj Menu Setting top marginPrint tests Select Registration Select Top Margin Hardware tests Select Single or ContinuousFollowing hardware tests can be selected from this menu LCD test Button testParallel wrap test ROM memory test Serial wrap test Dram memory test Transmit Data Interrupt Error Duplex tests Duplex left marginSelect Duplex Test Select Duplex Left Margin Disk test/clean Device testsQuick disk test Flash test Select either Color Page Counts or Mono Page Counts Printer setupSetting the page count Viewing the permanent page count Serial number Setting configuration ID Parallel strobe adjustment Error log Viewing the error logPrinting the error log Restore EP factory defaults Clearing the error log Exiting diagnostic mode 5021-0XX Repair information Removal and cleaning precautions During inspection During replacementHandling the printed circuit boards with MOS ICs During transportation/storage Photodeveloper cartridge HandlingParts not to be touched Precautions to take before maintenance work Printer removal procedures CRU/FRU and supplies removals Transfer belt cleaning roller removal Cleaning roller cover removal Transfer belt unit removal Transfer roller removal Fuser assembly removal Open front cover Remove waste toner bottle Waste toner bottle removal Photodeveloper cartridge removal 5021-0XX Duplex unit assembly removal 5021-0XX Lift duplex unit up and away from printer Repair information Secondary paper feed assembly removal Cover removals Top cover assembly removal Front cover assembly removal 5021-0XX 5021-0XX Right cover removal Rear cover assembly removal 5021-0XX Left cover removal Laser unit assembly printhead removal 5021-0XX Laser unit fan assembly removal Erase lamp removal 5021-0XX Right side removals Front door interlock switch removal 5021-0XX Developer motor removal Front door interlock switch with bracket Waste toner bottle holder removal Developer drive assembly removal 5021-0XX 5021-0XX Toner sensor sender removal Cleaning roller clutch removal 5021-0XX Main motor assembly removal 5021-0XX Clutch removal Remove fuser clutch. See Clutch removal on Main drive gear assembly removal Waste toner feeder removal Remove main drive gear assembly from printer 5021-0XX Rear removals RIP board removal Bracket assembly removal Paper guide assembly removal Paper guide C assembly removal Paper feed roller removal Paper exit assembly removal Remove two screws C 5021-0XX Remove transfer roller. See Transfer roller removal on Registration assembly removal Left side removals Remove left cover. See Left cover removal on Operator panel cable removal Engine controller board removal 5021-0XX RIP board cage removal Remove ducting Disconnect all connectors from Hvps Repair information High voltage power supply Hvps removal Low voltage power supply Lvps with cage removal 5021-0XX Hvps cage removal Remove HVPS. See High voltage power supply Hvps removal on Remove four screws C remove Hvps cage Toner present sensor removal Toner retract solenoid and cam removal Toner sensor receiver removal Left tray guide assembly removal 5021-0XX 5021-0XX Top removals Marker sensor assembly removal Board removal Do not remove the jumper Waste toner auger removal Waste toner agitator removal Power supply fan removal Printer Locations and connectors Part name Description Options Sensor locations Electronic components TNK Name Function Printer circuit board locations Fan/motor locations Interlock switch locations Fbcl Solenoid/clutch locations Toner retract Symbol Part name Symbol and part name table LDU TTR Trcm Wiring diagram / cable harness reference RIP board Engine controller board Input/output I/O board 5021-0XX Engine controller board I1CN-I/O board DCN1 Printer cables 5021-0XX OAD1 OAD2 Sgnd DCN3 Engine controller board I2CN-I/O board DCN3 5021-0XX Engine controller board HVCN-HVPS CN1 Hvcn Engine controller board P2CN-Operator panel Board DCN13-LVPS ACN1 Lvps ACN2-Interlock switches Board DCN18-Interlock switchesInterlock switches-Interlock switches Lvps ACN5-Engine controller board Lvcn Lvps ACN5-Engine controller board DCN21 No connection ACN3 Engine controller board POCN-LVPS ACN3 DCN4 Board DCN4-Toner retract solenoids 5021-0XX Board DCN5-Photodeveloper OPC marker sensor Board DCN8-Laser fanBoard DCN15-Toner present sensor, erase lamp Tleschk Sgnd DCN16 Board DCN16-Sensors DCN7 Board DCN7-Rear cover assembly Htfanerr DCN10 DCLCON-N Board DCN12-Main motor 5021-0XX Board DCN11-Developer motor Mmenc MMREV-N Mmgain Mmovld LDU Engine board LCN-Printhead LDU Sgnd SCMRDY-N Scmclk Pgnd SCMON-N DCN14 Board DCN14-Lower feeder unit LFCN-CHK-N DCN19 Board DCN19-Paper size sensor and temperature thermistor Fuser connector-LVPS 240V Printer Fuser connector-LVPS 120V Printer Engine controller board FUCN-fuser 5021-0XX Engine controller board DPCN-Duplex unit Dupl Lvps ACN4-Duplex unit Dupl and duplex power Duplex Preventive maintenance 5021-0XX Parts catalog How to use this parts catalog Assembly 1 Base printer Index Units Description Assembly 1 Base printer Assembly 2 Covers Assembly 2 Covers Assembly 3 Front Assembly 3 Front Assembly 4 Right Assembly 4 Right Assembly 5 Rear Assembly 5 Rear Assembly 6 Left Assembly 6 Left Assembly 7 Top Assembly 7 Top Assembly 8 RIP board Assembly 8 RIP board Assembly 9 Miscellaneous/Options DIMM, 128MB Sdram Assembly 9 Miscellaneous/Options Assembly 9 Miscellaneous/Options Index Paper transportation system 5021-0XX 5021-0XX Part number index 5021-0XX 5021-0XX 5021-0XX